FIELD OF THE INVENTION

The present invention relates to a barrier system in which one or more barrier elements (such as a rail) is supported on posts or stanchions, and to a method of assembly of the system. In particular aspects, the invention relates to a stanchion for such a system and method of manufacture thereof, and to a rail support provided to support rails upon a stanchion.

Such barrier systems are typically installed for safety purposes at the edge of walkways, stairs or balconies and it will be convenient to hereinafter describe the invention for such applications and with reference to barrier rail systems as well as with rails. However, it should be appreciated that the invention is not limited thereby as it has other applications also and may be used with panels, chains and the like.

BACKGROUND TO THE INVENTION

Prior art barrier rail systems are typically formed from tubular steel. Tubular steel rails are mounted to tubular steel stanchions in order to provide sufficient strength and resistance to loads that may be imposed on the system. Tubes have excellent strength properties relative to the mass of material used, including good resistance to bending forces.

There are a number of ways in which a rail may be mounted to a stanchion. A common one, and one that has good strength properties, is to provide a tubular stanchion having a tubular sleeve through which the rail is passed to assemble the barrier system.

For a stanchion for supporting a knee rail and a hand rail the stanchion will thus have a lower vertical tube section, welded to a perpendicular tubular sleeve at knee height, and an upper vertical tube section, welded to the knee height sleeve and to a further perpendicular tubular sleeve at waist or hand height. To install the barrier rail system, stanchions are mounted to the floor and the rail is threaded through the appropriate sleeve in each of the stanchions. The rail, once positioned, is then welded in place to fix it to the stanchion.

If the rail must be angled, bent or curved, for example around a corner, it is threaded through the sleeve of an installed stanchion and then bent to suit. Alternatively, two sections can be threaded through adjoining stanchions and joined {eg welded) to create the bend required. Where a rail is not horizontal, eg on a stair well, the sleeve(s) are not perpendicular to the vertical tube sections, but rather angled appropriately.

The above is a costly labour intensive process which can deliver aesthetically displeasing results. It would be desirable to provide an improved barrier rail system that addresses one or more of the issues.

SUMMARY OF THE INVENTION

A first aspect of the present invention provides a stanchion folded from a sheet, the stanchion including:

a body portion;

a brace portion connected to the body portion; and

a base portion connected to the body portion;

a first axis about which the brace portion is angled relative to the body portion; and

a second axis about which the base portion is angled relative to the body portion; wherein the first axis and second axis are substantially perpendicular relative to each other.

Preferably the stanchion is formed from a blank of sheet metal, the sheet metal blank folded to have a first fold defining the first axis and a second fold defining the second axis.

Preferably the brace portion is angled at an angle of between 45 degrees to 135 degrees to the body portion, preferably at an angle of between 80 degrees to 100 degrees, and more preferably the brace portion is angled at a substantially perpendicular angle to the body portion. Preferably the base portion is angled at an angle of between 45 degrees to 135 degrees to the body portion, preferably at an angle of between 80 degrees to 100 degrees, and more preferably the base portion is angled at a substantially perpendicular angle to the body portion.

In a preferred embodiment the brace portion is in register with the base portion and the brace portion is permanently or releasably fixed to the base portion. Preferably the brace portion is fixed to the base portion by a weld, spot weld, adhesive, fastener or bracket.

In a preferred embodiment each of the body portion, brace portion and base portion extend in mutually perpendicular planes from each other. Preferably each of the body portion, brace portion and base portion are substantially planar and the planes of the body portion, brace portion and base portion are mutually substantially perpendicular.

Advantageously, this provides an easily manufactured and easy to install product of low material and labour costs and good strength, as discussed in more detail herein.

Preferably the base portion includes at least one mounting zone for mounting the stanchion in a use position and preferably the or each mounting zone includes at least one mounting hole for cooperation with mounting device(s).

A second aspect of the present invention provides a blank for making a stanchion, the blank having:

a body portion;

a brace portion connected to the body portion;

a base portion connected to the body portion;

a first axis defining a boundary between the brace portion and the body portion; a second axis defining a boundary between the base portion and the body portion, wherein the first and second axis are substantially perpendicular.

Preferably the blank includes a void space extending:

from a point located at the intersection of the second axis with an edge of the brace portion;

to a point located on the first axis. Preferably the blank is of sheet metal.

Preferably the stanchion or blank of the first and second aspects provides:

a first support zone for supporting a rail, the rail having a predetermined diameter;

the first support zone including a first projection and a second projection disposed in predetermined spaced apart relation;

wherein the first projection and the second projection are shaped to each provide a substantially point contact support to the rail when in use, whereby a clearance gap between the rail and stanchion is created.

Preferably the stanchion or blank includes a recess having a mouth, wherein; the first support zone is located in the recess;

the mouth has a predetermined size and orientation to enable, during installation, positioning of the rail upon the first projection and the second projection by movement of the rail solely perpendicular to the longitudinal axis of the rail.

A preferred embodiment of the stanchion or blank includes a trade mark, message, information or decoration on the body portion, brace portion or base portion.

A third aspect of the present invention provides a method of making a stanchion including the steps, in any order, of:

folding a blank along a first axis to angle a brace portion relative to a body portion;

folding the blank along a second axis to angle a base portion relative to the body portion;

wherein the first axis and second axis are substantially perpendicular relative to each other.

A fourth aspect of the present invention provides a method of making a blank for making a stanchion, the blank including:

a body portion and a brace portion connected to the body portion;

a base portion connected to the body portion;

a first axis about which the brace portion is angled relative to the body portion; a second axis about which the base portion may be angled relative to the body portion;

wherein the first and second axis are substantially perpendicular;

including the step of:

cutting or pressing the blank from a sheet, including cutting or pressing a void space and a trade mark, message, information or decoration on the body portion, brace portion or base portion.

A fifth aspect of the present invention provides a method of making a blank for making a stanchion, the blank having:

a body portion and a brace portion connected to the body portion;

a base portion connected to the body portion;

a first axis about which the brace portion is angled relative to the body portion; a second axis about which the base portion may be angled relative to the body portion;

wherein the first and second axis are substantially perpendicular;

including the step of:

overmolding the body portion and the brace portion in a plastic matrix to connect the body portion to the brace portion

whereby a user may make the stanchion by folding the base portion relative to the body portion along the second axis.

A sixth aspect of the present invention provides a barrier system including:

a stanchion according to any of the previous aspects; and

at least one rail supported by the stanchion.

A seventh aspect of the present invention provides a stanchion including:

a first support zone for supporting a rail, the rail having a predetermined diameter and a longitudinal axis;

the first support zone including a first projection and a second projection disposed in predetermined spaced apart relation; wherein the first projection and the second projection are shaped to each provide a substantially point contact support to the rail when in use, whereby a clearance gap between the rail and stanchion is created.

Preferably the stanchion includes a recess having a mouth, wherein;

the first support zone is located in the recess;

the mouth has a predetermined size and orientation to enable, during installation, positioning of the rail upon the first projection and the second projection by movement of the rail solely perpendicular to the longitudinal axis of the rail.

Preferably the stanchion includes:

a body portion;

a brace portion connected to the body portion; and

a first axis about which the brace portion is angled relative to the body portion.

Preferably the first support zone is located on either or both of the body portion and brace portion. In one embodiment the support zone is located in an edge region of the brace portion or is located in the region of the first axis. In another embodiment the first projection is located on the body portion in the region of the first axis and the second projection is located on the brace portion in the region of the first axis. Preferably each of the first projection and the second projection is a convex tab.

Preferably the stanchion further includes:

a second support zone for supporting a second rail having a predetermined diameter;

the second support zone including a third projection and a fourth projection disposed in predetermined spaced apart relation;

wherein the third projection and the fourth projection are shaped to each provide a substantially point contact support to the second rail when in use, whereby a clearance gap between the second rail and stanchion is created.

An eighth aspect of the present invention provides a blank for making a stanchion including:

a first support zone for supporting a rail, the rail having a predetermined diameter; the first support zone including a first projection and a second projection disposed in predetermined spaced apart relation;

wherein the first projection and the second projection are shaped to each provide a substantially point contact support to the rail when in use, whereby a clearance gap between the rail and stanchion is created.

A ninth aspect of the present invention provides a barrier system including:

a stanchion according to the seventh aspect of the invention; and

a rail having a predetermined diameter and having a longitudinal axis.

Preferably the centre of gravity of the rail acts in a direction intersecting with a line between the first projection and the second projection; and the rail is supported in a stable position upon the first projection and the second projection of the stanchion, through the action of gravitational forces.

Preferably the further includes a second rail having a predetermined diameter and having a longitudinal axis. Preferably at least one of the rails has a circular cross section.

A tenth aspect of the present invention provides a method of installing a barrier system having a stanchion and a rail;

the stanchion having a first support zone for supporting the rail, the first support zone including a first projection and a second projection disposed in predetermined spaced apart relation;

the rail having a predetermined diameter and a longitudinal axis including the steps of :

positioning the rail in contact with the first projection and the second projection; whereby the first projection and the second projection each provide a substantially point contact support to the rail whereby a clearance gap between the rail and stanchion is created.

Preferably the stanchion includes a recess having a mouth, the first support zone is located in the recess and the mouth has a predetermined size and orientation, further including the step of positioning of the rail upon the first projection and the second projection by movement of the rail substantially in one or more directions perpendicular to the longitudinal axis of the rail.

Preferably the method further includes the steps of:

welding the rail to the stanchion at the first projection and at the second projection; and galvanising or coating the weld zone.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of one or more preferred embodiments of the present invention will be readily apparent to one of ordinary skill in the art from the following written description with reference to and, used in conjunction with, the accompanying drawings showing preferred embodiments of the invention, in which:

Figure 1 is a perspective view of a barrier rail system according to a preferred embodiment of the invention;

Figure 2a is a perspective view of a stanchion according to a preferred embodiment of the present invention;

Figure 2b is a perspective view of the stanchion on Figure 1 a, further including rails;

Figure 3a is a side view of the stanchion of Figure 1 a;

Figure 3b is a side view of the stanchion of Figure 1 a, further including rails; Figure 4a is a plan view of a blank for making the stanchion of Figure 1 a;

Figure 4b is a perspective view of the blank of Figure 4a, in which the brace portion has been folded relative to the body portion;

Figures 5a and 5b are detailed views of support zones. DESCRIPTION OF PREFERRED EMBODIMENT

Figure 1 shows a barrier system 8 having a plurality of stanchions 2 supporting a plurality of longitudinal rails 4: foot rail 91 which could be a flat board or as shown is of rectangular cross section, tubular knee rail 71 of circular cross section and tubular hand rail 81 of circular cross section. The stanchions 2 are secured with bolts 64 that pass through holes in the lower end of the stanchions, to a walkway edge 120. The rails 4 extend parallel to the walkway edge 120. The rails 4 may be of continuous lengths or of discrete sections joined together to form the rails.

Each rail 4 is supported by the stanchion 2 and may be supported further along its length by a second stanchion 2' and subsequent stanchions (not shown). Alternatively, the rail could be affixed to other forms of support such as a wall bracket or the like as appropriate to a particular location. Discussions herein encompass a plurality of stanchions supporting a knee rail, hand rail and foot rail however variations fall within in the scope of the invention as claimed herein. The term "rail" is used for convenience herein, and includes various barrier members, including cables, chains, brackets supporting panels and the like. It is not restricted to substantially inflexible or rigid elongate members. For example, in some situations, chains or netting may be more appropriately used, together with the stanchions of the invention. It may be appropriate to provide a rail section in combination with other barrier members, for example a short length of rail to which netting or chain is attached and to mount the barrier member to the stanchion via the rail section.

Each stanchion 2 supports the weight of the rails 71 , 81 , 91 and positions the rails 71 , 81 , 91 at the appropriate heights and spacings to address safety requirements. Additional rails or alternative spacing could be provided in similar manner if required in a particular location or to meet a particular safety code.

Figures 2a and 3a show a stanchion 2 having an elongate first portion 10 (also referred to as the body portion 10) connected to an elongate second portion 20 (also referred to as the brace portion 20). In use in a standard installation the body portion 10 of this embodiment is substantially vertical. The body portion 10 and brace portion 20 are integrally formed from a sheet of metal and folded about a first axis 40 to extend in different planes from each other. The first portion 10 and second portion 20 are thus angled relative to each other, creating an "L" shaped cross section with the body portion 10 forming one arm of the "L" and the brace portion 20 forming the other arm. Preferably the body and brace portions are angled at between 45 degrees to 135 degrees from each other, more preferably between 80 degrees and 100 degrees relative to each other, and most preferably at about 90 degrees to each other. It should be noted that the cross section is not necessarily constant along the height of the stanchion and that the length of the two arms may vary. In Figure 2a, the body portion 10 forms an arm of substantially constant length, but the brace portion 20 forms an arm that is longer at the lower end of the stanchion and shorter at the upper end. The stanchion 2 also includes a third portion 30 (also referred to as the base portion 30) connected to the body or first portion 10. The base portion 30 is also integrally formed from the same sheet of metal. The body portion 10 and base portion 30 are folded about a second axis 50 that in use in a standard installation the base portion 30 is substantially horizontal, such that each of the portions 10, 20 and 30 extend in different planes from each other. The third portion 30 is thus angled relative to both the first portion 10 and to the second portion 20.

As shown in the embodiment, the first axis 40 is vertical and second axis 50 is horizontal and thus they are substantially perpendicular to each other, regardless of the planes in which the body, brace and base potions extend. In the preferred embodiment the planes in which the body portion, brace portion and base portion extend are substantially mutually perpendicular to each other.

The base portion 30 has a mounting zone 60 including mounting holes 62. The stanchion as shown in Figure 2a may therefore be mounted upon a horizontal surface such as a walkway edge 120, or across a roadway or other location a barrier is required. Mounting device(s) such as bolts 64 as shown in Figure 1 , or other fastening means such as adhesives, cement, fasteners, recessed slots, keyed fasteners, U-bolts with pins etc may be used to secure the stanchion 2 to the horizontal surface, permanently or removably (as in some situations it may be useful to allow occasional passage of authorised vehicles, lifting hoists etc).

The stanchion may be made from a suitable blank of sheet metal 102 having first (body), second (brace) and third (base) blank portions 1 10, 120 and 130 respectively, as shown in Figure 4a. The blank is formed to include appropriate rail support zones 70, 80 and mounting zones, and includes a void space 106.

The void space 106 is located such that the second blank portion (brace portion) 120 is separated from the third blank portion (base portion) 130 when the blank is a flat sheet. Both the brace portion 120 and base portion 130 are connected to the body portion 1 10. The blank 102 of Figure 4a has a triangular void space 106, which extends in a diagonally upward direction from an edge of the blank, with the acute point of the triangle located away from the outer edge of the blank.

The blank 102 is then folded about the vertical first blank axis 140, and the horizontal second blank axis 150 to form the triangulated stanchion 2. Ideally the brace portion 20 is brought into register with the base portion 30 such that a weld may be made between base and brace portions. This provides the structure with additional rigidity. Desirably, the brace portion 20 is spot welded to the base portion 30 at a point 24 that is consistent on each stanchion in a barrier system.

The use of the triangular void 106 provides clearance between the majority of the base portion and the brace portion, resulting in a single (and consistent) location, point 24, at which a spot weld is applied. Thus, each stanchion will be the same as the next, without need for elaborate measurement to determine the position of the spot weld. Furthermore, there is no need to do a long weld, which may be aesthetically displeasing if not done carefully and is less likely to present uniform appearance.

In alternative embodiments, the void space in the blank may be shaped in a variety of ways and is not limited to triangular configurations. In the embodiment shown in the figures, the void space 106 extends from a point located at the intersection of an edge of the brace portion (the outer or free edge, not connected to the body portion) with the second axis 150 (which becomes the second axis 50 of the stanchion once the blank is folded to form the stanchion 2), to a point located on the first axis 140 (which becomes the first axis 40 of the stanchion once the blank is folded to form the stanchion 2).

Since in practice it is both useful and effective to use the edge or limit of the void space as a guide for folding the blank along the first and second axes, it can be said that the limits of the void space define the first 140 and second axes 150 of the blank. However, it remains possible to use a differently shaped void or create a fold in such a blank along an axis that extends through the void space, or in the case of the second axis, avoids the void space, to obtain a stanchion with many advantages over the prior art. Thus a stanchion according to the invention should not be considered limited only to stanchions made from blanks in which the folds are made at the limit of a void space.

Manufacture of the stanchion 2 is thus extremely inexpensive and easy. It may be made from readily available materials and shipped to the installations site in flat form, or may be prefabricated into ready to install stanchions prior to shipping. An intermediate form 102' as shown in Figure 4b may also be shipped, in which the blank has been folded along the first blank axis 140, but the shorter fold along the second blank axis is done on site. This enables very efficient packing of the partially formed stanchions, as well as efficient installation and the ability to adapt stanchions to suit specific conditions, such as may be encountered at the bend in a stairwell or the end of a walkway. It should be noted that in an alternative, not shown, the brace portion may be bent at an angle away from the base portion - that is, the base portion protrudes from one side of the body portion, while the brace portion protrudes from the other side. This may be useful for specific sites where there is insufficient room for the base portion to be installed in a usual orientation, or where it is desired that the brace portion should face outward from a walkway edge rather than inwardly.

It is also noted that the stanchions of the present invention may be installed in any orientation, for example by being rotated 45 degrees or 90 degrees from the angles shown in the barrier system of Figure 1. In addition to supporting the mass of rails 71 , 81 , 91 , against the force due to gravity, the stanchions 2 also resist loads applied to the rails or stanchions by people, animals, objects etc, whether deliberate or of low magnitude (such as a person using a handrail while climbing stairs) or accidental or of high magnitude such as an accidental impact load due to animate or inanimate load impacting the barrier rail system 8 at speed. The various forces or loads applied to the stanchions 2 could be applied directly to the stanchion 2, or may be applied indirectly, being transmitted to the stanchion 2 via an intermediary such as the rail(s).

The stanchions 2 therefore, in use, may be expected to receive loads from a variety of directions or vectors and at a variety of locations. These loads can be applied vertically to the stanchion(s) or rail(s), or horizontally to the stanchion(s) or rail(s), or be a combination. Horizontal forces can be applied perpendicular to the longitudinal rails or at a non-perpendicular angle and in particular where a force is applied to a rail, it is noted that the force transmitted to the adjacent stanchion(s) will have a significant component parallel to the longitudinal rails, as the rail 'pulls' upon the stanchion(s). Preferably the barrier rail structure 8 is arranged to enable a load applied at a point to be distributed through the structure so that two or more stanchions resist the load.

In addition to impact and shear force loads, loads applied to the top end of a stanchion 2 (secured at its lower end to the walkway edge) create a bending load or moment on the stanchion. The stanchion needs to be strong enough that under loads expected in service it is unlikely to bend and thus functions to prevent, eg, a person, from falling over the edge of the walkway.

The "L" shaped cross section of the body and brace portions of the stanchion makes it less likely to bend or buckle under loads than a solid rectangular cross section having the same amount of material. The geometry of the stanchion provides additional strength without the needs for additional volume of material, for example compared to a metal strip. The brace portion 20 serves as a reinforcing element where a load is applied to the body portion 10, and vice versa. The first portion 10 has been nominated as the body portion, and the second portion 20 as the brace portion, but it should be noted that a load could be applied to either or both portions, and that as the two portions brace each other, the relative sizes of each portion can vary significantly - the brace portion could be larger or smaller than the body portion. Furthermore, the triangulation of the base portion with the body and brace portions, such as through spot welding the brace portion to the base portion, provide even greater structural strength and rigidity to the stanchion. The excellent safety qualities of tubular stanchions may be replicated, but in a form that is much cheaper and easier to manufacture, store, ship and install. The stanchions and barrier system may also be more aesthetically pleasing, as if desired it is possible to avoid long welds but instead use spot welds and to position these consistently.

Another advantage of making stanchions and blanks from a sheet is that it is inexpensive and simple to provide interesting shapes and designs that are easily produced when cutting or stamping the blank from the original sheet, or even when folding a blank into a stanchion. The shape of the body portion, brace portion and base portion can be designed or selected for artistic and aesthetic purposes, creating an attractive architectural feature.

Furthermore, a trade mark, message, information or decoration may be provided on the body portion, brace portion or base portion, for example safety and commercial information or advertising, warning of dangers in the area or promoting the trade mark of the suppliers of products, the builder of an industrial plant, firm of architects and the like. They can be adhered, engraved, coated, impressed or embossed, or formed by cutting, pressing or punching or other known methods. Manufacture of a stanchion from a sheet or blank makes it simple to use such methods whether as a step in manufacture of a blank, or in manufacture of the stanchion from the blank.

As shown in Figure 1 and Figure 2b, the stanchion 2 may be used together with one or more rails 4 as the barrier system 8. The stanchion 2 of Figures 2a and 2b has a first support zone 70 for supporting the tubular knee rail 71 of circular cross section, a second support zone 80 for supporting the tubular hand rail 81 of circular cross section and a third support zone 90 for supporting the foot rail 91 of rectangular cross section.

The first support zone 70 for supporting knee rail 71 is located within a recess, in order to receive (or partially receive) the knee rail within the profile of the stanchion 2. The recess is Open' to an edge of the stanchion, formed in an edge of the brace portion 20. In alternative embodiments, the recess may be formed an edge of the body portion 10, in an edge of both the body portion 10 and the brace portion 20 (in which case the rail may be supported by both the body and brace portions), or even in the edge formed along the first axis 40 about which the body and brace portions 10,20 are angled relative to each other. Thus the recess can be provided at an outer free edge (edge region) of the body or brace portions, or can be located in the region of the first axis 40.

The knee rail 71 may easily be mounted to the stanchion 2 through lateral movement of the rail 71 in a direction that may be solely perpendicular to the longitudinal axis 5 of the rail, that is, without needing to move it in the direction parallel to the rail. The lateral or perpendicular movement to mount the rail on the support zone is herein referred to as 'sideways movement', although in many instances it may have a vertical aspect. The ability to mount the rail through sideways movement enables swift assembly of the stanchions and rails into a barrier system. Mounting the rail in the support zone is merely a matter of moving it substantially sideways into the recess, and then moving along to the next stanchion to repeat the process. If several workers are available, the rail can be mounted on a number of stanchions at the same time.

The prior art alternative, where the support zone consists of a sleeve or hole through which the rail must be threaded, is time consuming particularly when the rail is of some length and has little flexibility. Indeed, on some situations, such as in stairwells or other confined spaces, it is not possible to thread a long rail length through the sleeve of an installed stanchion and many unsightly and time consuming joins must be made to connect numerous rail segments into a whole. Furthermore, where the rail must be bent or curved, it cannot be threaded through the sleeve, which means it must be installed on the installed stanchion prior to bending etc. This results in uneven and inconsistent results, aside from the additional labour and installation time needed. In contrast, the present invention allows for rails to be delivered to site already bent to shape, for any bends to be made uniform in a factory setting where this is much quicker and easier, and to simply be lifted sideways into place during installation. The foot rail support zone 90 shown in the Figures is suited to a rail of rectangular cross section. Such a rail is mandated under Australian standards. However, in other situations it may be desirable to provide a support zone for the foot rail similar to that provided for the knee rail.

The hand rail support zone 80 is described in further detail below. However, it is noted that again, 'sideways' movement is used to position the rail 81 , again avoiding the longitudinal movement required to thread a rail through a sleeve. In this case, the perpendicular, lateral or 'sideways' movement is actually substantially vertical.

As discussed, the stanchion 2 of Figures 2a to 3b has a first support zone 70, for supporting the knee rail 71 and a second support zone 80 for supporting the hand rail 81.

Figure 5a shows the detail of the first support zone 70 and Figure 5b the second support zone 80. This arrangement is shown in more detail in Figures 5a and 5b, being partial detail views of the views from Figures 3a and 3b. The first support zone 70 is located within a recess 76 having a mouth 78. Located within the recess are a first projection 72 and a second projection 74.

The knee rail 71 has a longitudinal axis and a predetermined diameter. It is supported by and rests upon the first projection 72 and second projection 74, which are spaced apart a distance to suit the predetermined rail diameter. The first projection 72 and the second projection 74 are shaped to each provide a substantially point contact support to the rail 71 when in use, whereby a clearance gap 73 between the rail and stanchion is created.

The centre of gravity of the rail falls between the first projection 72 and the second projection 74, such that the rail is stable and sits upon the first projection 72 and second projection 74 under its own weight. Thus, the rail 71 does not need to be clamped or otherwise supported as the barrier system is assembled. Typically the rail will be a tube of circular cross section, but many other cross sections are possible and may, for example, have a centre of gravity that is not aligned with the geometric centre of the cross section. This would allow alternative configurations of the projections, provided the centre of gravity still fell between them.

As shown in Figure 5b, the second support zone 80 has a recess or clearance gap 86 disposed between a first projection 82 and a second projection 84. A tubular hand rail 81 can therefore rest on the first and second projections 82,84 with its centre of gravity falling between the projections.

Once a rail has been positioned, for example along a section of barrier system including several stanchions, it may be permanently affixed to the stanchion by welding. The rail is supported in a stable position, and at the same location, on each of the several stanchions. It is therefore a simple matter to apply a spot weld between a rail 71 ,81 and the first projection 72,82 and between the rail 71 ,81 and the second projection 74,84 and as this point of contact is largely a point contact, the person performing the weld is forced to apply that weld at the same location for each stanchion - resulting in an aesthetically pleasing and efficiently made series of welds. Furthermore, it is only necessary to make a spot weld rather than an elongate weld extending along the circumference of the rail. This reduces the likelihood of ugly welds as well as reducing the time taken to perform the welds.

Advantageously, once a rail 71 ,81 is welded to the stanchion 2, a clearance gap 73, 86 remains between the rail 71 ,81 and the stanchion 2 - the only points of contact are the weld points located on the first projection 72,82 and second projection 74,84. Thus the projections and the rail define a gap therebetween. The clearance between the rails 71 ,81 and stanchion 2 increases the effectiveness of on site galvanisation processes, as all weld or heat effected zones may be reached by the treatment, as well as touch-up paint or other coating processes. It is relatively easy for example for a brush to be used to apply paint or a coating to all heat effected areas. Therefore, the resistance of the stanchion to corrosion may be enhanced. Preferably as shown in the drawings, the projections are small tabs having a convex rounded contact surface as this makes for a substantially point contact and accurate and consistent spot welding, however, the projections may be in the form of pointed spikes, tabs with a flat contact surface etc to suit a predetermined size or shape of rail.

While the preferred embodiment as shown in the drawings is assembled though movement sideways of the rail onto the support zones, provision of such projections in an embodiment having a thread-through sleeve will also provide more effective on site galvanisation or other corrosion preventative measures. Thus such projections also fall within the scope of the invention.

In alternative embodiments, the stanchion blank may be folded along the first axis to form an angle (say 90 degrees) between the body and brace portions. The angled blank may then be molded or overmolded in rigid plastic or another suitable matrix/substance, leaving a base portion extending beyond the overmolded section. This may be useful to provide colourful stanchions, to mold in other features to the stanchions, to provide softer edges or avoid any sharp burrs, and will still function in the same manner as has been described above. After molding, the base portion may be folded prior to installation if needed, whether on site or in the factory. In yet a further embodiment, an integral stanchion blank may be formed by overmolding two sheet metal strips in rigid plastic to immediately obtain an angled integral stanchion blank.